Capped tufted laminate web

ABSTRACT

A laminate web having a nonwoven web in facing relationship with a polymer film. The laminate web has a first side comprising the polymer film and a plurality of discrete tufts including fibers integral with and extending from the nonwoven web. Each of the tufts has a tuft base proximal to the nonwoven web and a distal portion opposing the tuft base. At least part of the distal portion of each of the tufts is covered by a cap, each cap being an integral extension of said polymer film extending over the distal portion of a discrete tuft. The cap has a first opening including a location of rupture in the polymer film above which the tuft extends.

FIELD OF THE INVENTION

The disclosure herein relates generally to a capped tufted laminate weband an article incorporating a capped tufted laminate web.

BACKGROUND OF THE INVENTION

Laminates of webs, such as films and fibrous webs are known in the art.For example, nonwoven webs are often laminated with polymer films suchthat they are useful as materials in disposable products such asbacksheets on disposable absorbent diapers. In such laminates thenonwoven portion can provide softness while the film portion can providefor fluid impermeability.

Laminates in which nonwoven fibers protrude through a polymer film canbe useful for providing an absorbent structure in which the nonwovenacts as the conveyor of fluid from one side of the polymer film to theother. The laminate can be structured such that the fluid collectingside of the laminate is the polymer film and nonwoven fibers protrudethrough the polymer film to the fluid collecting side of the laminate.For example, in a sanitary napkin or diaper, such a laminate can bepractical for use as a topsheet that transports fluid from the bodyfacing surface of the sanitary napkin more deeply into the sanitarynapkin towards the absorbent core. If the fibers are structured as tuftsin which the fibers comprising the tuft generally converge near the baseof the tuft, the convergence of fibers can provide for small capillariesthat can aid in transporting the fluid through the topsheet. Further,the fibers protruding through the polymer film can have a pleasanttactile impression.

Depending on the arrangement of the fibers of the nonwoven protrudingthrough the polymer film and the fluid acquired by the tufts, the fiberson the fluid collecting side of the film may retain some fluid in smallcapillaries that might exist between the fibers. If the laminate is anabsorbent article, such a sanitary napkin, diaper, or tampon, this mayresult in the retained fluid appearing as a stain on the body facingsurface of the laminate. Stains of menses, vaginal discharge, urine, andfeces may not be viewed favorably by the wearer of the absorbentarticle. If the laminate is used in a wipe or cleaning device, theretained fluid may be visually perceptible to the user of the device andthe user may misinterpret the staining as an indication that the utilityof the wipe or cleaning device is exhausted even when such adetermination is in reality premature.

With this limitation in mind, there is a continuing unaddressed need fora laminate of a polymer film and fibrous web in which the fibrous webprotrudes through the polymer film that has improved capabilities formasking fluid retained in the fibers protruding through the polymerfilm.

SUMMARY OF THE INVENTION

Disclosed herein is a laminate web comprising a nonwoven web in facingrelationship with a polymer film, the laminate web comprising a firstside comprising the polymer film and a plurality of discrete tuftscomprising fibers integral with and extending from the nonwoven web,wherein each of the tufts has a tuft base proximal to the nonwoven weband a distal portion opposing the tuft base, wherein at least part ofthe distal portion of each of the tufts is covered by a cap, each capbeing an integral extension of the polymer film extending over thedistal portion of a discrete tuft, the cap comprising a first openingcomprising a location of rupture in the polymer film above which thetuft extends.

Disclosed herein is an absorbent article comprising a topsheet in facingrelationship with an absorbent core, the topsheet comprising a laminateweb comprising a first side comprising the polymer film and a pluralityof discrete tufts comprising fibers integral with and extending from thenonwoven web, wherein the nonwoven web is between the polymer film andthe absorbent core, wherein each of the tufts has a tuft base proximalto the nonwoven web and a distal portion opposing the tuft base, whereinat least part of the distal portion of each of the tufts is covered by acap, each cap being an integral extension of the polymer film extendingover the distal portion of a discrete the tuft, the cap having a firstopening comprising a location of rupture in the polymer film above whichthe tuft extends.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a web of the present invention.

FIG. 2 is an enlarged view of a portion of the web shown in FIG. 1.

FIG. 3 is a cross-sectional view of section 3-3 of FIG. 2.

FIG. 4 is a cutaway plan view of a portion of the web as indicated by4-4 in FIG. 3.

FIG. 5 is a plan view of a portion of the web shown in FIG. 4.

FIG. 6 is a perspective view of an apparatus for forming the web of thepresent invention.

FIG. 7 is a cross-sectional depiction of a portion of the apparatusshown in FIG. 6.

FIG. 8 is a perspective view of a portion of the apparatus for formingone embodiment the web of the present invention.

FIG. 9 is an enlarged perspective view of a portion of the apparatus forforming the web of the present invention.

FIG. 10 is a partial cutaway plan view of a sanitary napkin of thepresent invention.

FIG. 11 is a partial cut away perspective view of a tampon of thepresent invention.

FIGS. 12-14 are scanning electron micrographs of a web of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a laminate web 1 of the present invention, hereinafterreferred to simply as web 1. Web 1 comprises at least two layers. Thelayers are referred to herein as generally planar, two-dimensionalprecursor webs, such as first precursor web 20 and second precursor web21. First precursor web 20 is a fibrous nonwoven web and secondprecursor web 21 is a polymer film. Precursor webs 20 and 21 (and anyadditional webs) can be joined by adhesive, thermal bonding, ultrasonicbonding and the like. As disclosed below, the constituent precursor websof web 1 can be joined by interlocking mechanical engagement resultingfrom the formation of tufts 6. A representative tuft 6 for theembodiment of web 1 shown in FIG. 1 is shown in a further enlarged viewin FIG. 2. A tuft can be a plurality of raised loops of fibers or a pileof fibers integral with and out of plane of the web from which the loopsor pile extend.

Web 1 has a first side 3 and a second side 5, the term “sides” beingused in the common usage of generally planar two-dimensional webs, suchas paper and films that have two sides when in a generally flatcondition. Each precursor web 20 and 21 has a first surface 12 and 13,respectively, and a second surface 14 and 15, respectively (shown inFIG. 3). The first surfaces 12 and 13 can be body facing surfaces andthe second surfaces 14 and 15 can be garment facing surfaces. Web 1 hasa machine direction (MD) and a cross machine direction (CD) as iscommonly known in the art of web manufacture. First precursor web 20 canbe a nonwoven web comprised of substantially randomly oriented fibers.By “substantially randomly oriented” is meant that, due to processingconditions of the precursor web, there may be a higher amount of fibersoriented in the MD than the CD, or vice-versa. For example, inspunbonding and meltblowing processes continuous strands of fibers aredeposited on a support moving in the MD. Despite attempts to make theorientation of the fibers of the spunbond or meltblown nonwoven webtruly “random,” usually a slightly higher percentage of fibers areoriented in the MD as opposed to the CD. Second precursor web 21 can bea polymer film or an apertured polymer film, such as a polyethylenefilm.

In one embodiment, first side 3 of web 1 is defined by exposed portionsof the first surface 13 of second precursor web 21 and at least one, butpreferably a plurality of, discrete tufts 6 which are integralextensions of the fibers of a nonwoven first precursor web 20. As shownin FIG. 3, each tuft 6 can comprise a plurality of looped, alignedfibers 8 extending through the first surface 13 of second precursor web21 and outwardly from the first surface 13 thereof In another embodimenteach tuft 6 can comprise a plurality of non-looped fibers 18 (as shownin FIG. 3) that extend outwardly from the first surface 13.

As used herein, the term “nonwoven web” refers to a web having astructure of individual fibers or threads which are interlaid, but notin a repeating pattern as in a woven or knitted fabric, which do nottypically have randomly oriented fibers. Nonwoven webs or fabrics havebeen formed from many processes, such as, for example, meltblowingprocesses, spunbonding processes, hydroentangling, airlaying, and bondedcarded web processes, including carded thermal bonding. The basis weightof nonwoven fabrics is usually expressed in grams per square meter(gsm). The basis weight of the laminate web is the combined basis weightof the constituent layers and any other added components. Fiberdiameters are usually expressed in microns; fiber size can also beexpressed in denier, which is a unit of weight per length of fiber. Thebasis weight of laminate webs suitable for use in the present inventioncan range from 10 gsm to 500 gsm, depending on the ultimate use of theweb 1.

The constituent fibers of nonwoven precursor web 20 can be comprised ofpolymers such as polyethylene, polypropylene, polyester, and blendsthereof. The fibers can comprise cellulose, rayon, cotton, or othernatural materials or blends of polymer and natural materials. The fiberscan also comprise a super absorbent material such as polyacrylate or anycombination of suitable materials. The fibers can be monocomponent,bicomponent, and/or biconstituent, non-round (e.g., capillary channelfibers), and can have major cross-sectional dimensions (e.g., diameterfor round fibers) ranging from 0.1-500 microns. For example, one type offibers suitable for the nonwoven web includes nanofibers. Nanofibers aredescribed as fibers having a mean diameter of less than 1 micron.Nanofibers can comprise all of the fibers in a nonwoven web or a portionof the fibers in a nonwoven web. The constituent fibers of the nonwovenprecursor web may also be a mixture of different fiber types, differingin such features as chemistry (e.g. polyethylene and polypropylene),components (mono- and bi-), denier (micro denier and >20 denier), shape(i.e. capillary and round) and the like. The constituent fibers canrange from about 0.1 denier to about 100 denier.

As used herein, “spunbond fibers” refers to small diameter fibers whichare formed by extruding molten thermoplastic material as filaments froma plurality of fine, usually circular capillaries of a spinneret withthe diameter of the extruded filaments then being rapidly reduced.Spunbond fibers are generally not tacky when they are deposited on acollecting surface. Spunbond fibers are generally continuous and haveaverage diameters (from a sample of at least 10) larger than 7 microns,and more particularly, between about 10 and 40 microns.

As used herein, the term “meltblowing” refers to a process in whichfibers are formed by extruding a molten thermoplastic material through aplurality of fine, usually circular, die capillaries as molten threadsor filaments into converging high velocity, usually heated, gas (forexample air) streams which attenuate the filaments of moltenthermoplastic material to reduce their diameter, which may be tomicrofiber diameter. Thereafter, the meltblown fibers are carried by thehigh velocity gas stream and are deposited on a collecting surface,often while still tacky, to form a web of randomly dispersed meltblownfibers. Meltblown fibers are microfibers which may be continuous ordiscontinuous and are generally smaller than 10 microns in averagediameter.

As used herein, the term “polymer” generally includes, but is notlimited to, homopolymers, copolymers, such as for example, block, graft,random and alternating copolymers, terpolymers, etc., and blends andmodifications thereof. In addition, unless otherwise specificallylimited, the term “polymer” includes all possible geometricconfigurations of the material. The configurations include, but are notlimited to, isotactic, atactic, syndiotactic, and random symmetries.

As used herein, the term “monocomponent” fiber refers to a fiber formedfrom one or more extruders using only one polymer. This is not meant toexclude fibers formed from one polymer to which small amounts ofadditives have been added for coloration, antistatic properties,lubrication, hydrophilicity, etc. These additives, for example titaniumdioxide for coloration, are generally present in an amount less thanabout 5 weight percent and more typically about 2 weight percent.

As used herein, the term “bicomponent fibers” refers to fibers whichhave been formed from at least two different polymers extruded fromseparate extruders but spun together to form one fiber. Bicomponentfibers are also sometimes referred to as conjugate fibers ormulticomponent fibers. The polymers are arranged in substantiallyconstantly positioned distinct zones across the cross-section of thebicomponent fibers and extend continuously along the length of thebicomponent fibers. The configuration of such a bicomponent fiber maybe, for example, a sheath/core arrangement wherein one polymer issurrounded by another, or may be a side-by-side arrangement, a piearrangement, or an “islands-in-the-sea” arrangement.

As used herein, the term “biconstituent fibers” refers to fibers whichhave been formed from at least two polymers extruded from the sameextruder as a blend. Biconstituent fibers do not have the variouspolymer components arranged in relatively constantly positioned distinctzones across the cross-sectional area of the fiber and the variouspolymers are usually not continuous along the entire length of thefiber, instead usually forming fibrils which start and end at random.Biconstituent fibers are sometimes also referred to as multiconstituentfibers.

As used herein, the term “non-round fibers” describes fibers having anon-round cross-section, and includes “shaped fibers” and “capillarychannel fibers.” Such fibers can be solid or hollow, and they can betri-lobal, delta-shaped, and are preferably fibers having capillarychannels on their outer surfaces. The capillary channels can be ofvarious cross-sectional shapes such as “U-shaped”, “H-shaped”,“C-shaped” and “V-shaped”. One practical capillary channel fiber isT-401, designated as 4DG fiber available from Fiber InnovationTechnologies, Johnson City, Tenn. T-401 fiber is a polyethyleneterephthalate (PET polyester).

As used herein, the term “integral” as in “integral extension” when usedfor the tufts 6 refers to fibers of the tufts 6 having originated fromthe fibers of the first precursor web 20. Therefore, the looped fibers 8and non-looped fibers 18 of tufts 6, can be plastically deformed andextended fibers of the first precursor web 20, and are, therefore,integral with first precursor web 20. As used herein, “integral” is tobe distinguished from fibers introduced to or added to a separateprecursor web for the purpose of making tufts, as is commonly done inconventional carpet making, for example.

As used herein, the term “integral” as in “integral extension” when usedfor the cap 7 refers to the substrate forming the cap 7 havingoriginated from the polymer film that is the second precursor web 21.Therefore, the cap 7 can be a plastically deformed extended substrate ofthe second precursor web 21, and is, therefore, integral with the secondprecursor web 21. As used herein, “integral” is to be distinguished froma substrate introduced to or added to a separate precursor web for thepurpose of making a cap 7.

As used herein, the term “opacity” refers to the property of a substrateor printed substrate which measures the capacity of the substrate tohide or obscure from view an object placed behind the substrate relativeto the point from which observation is made. Opacity can be reported asthe ratio, in percent, of the diffuse reflectance of a substrate backedby a black body having a reflectance of 0.5% to the diffuse reflectanceof the same substrate backed with a white body having an absolutereflectance of 89%. Opacity can be measured as described in ASTM D589-97, Standard Test Method for Opacity of Paper (15°/DiffuseIlluminant A, 89% Reflectance Backing and Paper Backing).

A substrate high in opacity will not permit much, if any, light to passthrough the substrate. A substrate having low opacity will permit much,if not nearly all, light to pass through the substrate. Opacity canrange from 0 to 100%. As used herein, the term “low opacity” refers to asubstrate or printed substrate having opacity less than 50%. As usedherein, the term “high opacity” refers to a substrate or printedsubstrate having opacity greater than or equal to 50%. As used herein,the term “opaque” refers to a substrate or printed substrate that has anopacity greater than or equal to 50%.

As used herein, the term “adjacent” means not distant and implies anabsence of anything of the same kind in between the structures that areadjacent.

The number, spacing, and dimensions of tufts 6 can be varied to givevarying texture to first side 3 of web 1. For example, if tufts 6 aresufficiently closely spaced the first side 3 of web 1 can have a terrycloth-like feel. Alternatively, tufts 6 can be arranged in patterns suchas lines or filled shapes to create portions of a laminate web havinggreater texture, softness, bulk, absorbency or visual design appeal. Forexample, when tufts 6 are arranged in a pattern of a line or lines, thetufts can have the appearance of stitching. Likewise, the sizedimensions, such as the height, length and width of individual tufts 6can be varied. Single tufts can be as long as about 3 cm in length andcan be made alone or dispersed among tufts of various sizes.

First precursor web 20 can be a fibrous woven or nonwoven web comprisingfibers having sufficient elongation properties to have portions formedinto tufts, as described more fully below. Tufts are formed by urgingfibers out-of-plane in the Z-direction at discrete, localized, portionsof first precursor web 20. The urging out-of-plane can be due to fiberdisplacement, i.e., the fiber is able to move relative to other fibersand be “pulled,” so to speak, out-of-plane. More often, however, formost nonwoven first precursor webs 20, the urging out-of-plane is due tothe fibers of tufts 6 having been at least partially plasticallystretched and permanently deformed to form tufts 6. Therefore, in oneembodiment, depending on the desired height of tufts 6, the constituentfibers of a nonwoven first precursor webs 20 can exhibit an elongationto break of at least about 5%, of at least about 10%, of at least about25%, of at least about 50%, or of at least about 100%. Elongation tobreak can be determined by simple tensile testing, such as by use ofInstron tensile testing equipment, and can generally be found onmaterial data sheets from suppliers of such fibers or webs.

It can be appreciated that a suitable nonwoven first precursor web 20should comprise fibers capable of experiencing sufficient plasticdeformation and tensile elongation, or are capable of sufficient fibermobility, such that looped fibers 8 are formed. However, it isrecognized that a certain percentage of fibers urged out of the plane ofthe first surface 12 of first precursor web 20 will not form a loop, butinstead will break and form loose ends. Such fibers are referred toherein as “loose” fibers or non-looped fibers (i.e. loose fiber ends) 18as shown in FIG. 3. Non-looped fibers 18 are not necessarily undesirablefor the present invention, and in some embodiments, most or all of thefibers of tufts 6 can be non-looped fibers 18. Non-looped fibers 18 canalso be the result of forming tufts 6 from nonwoven webs consisting of,or containing, cut staple fibers. In such a case, some number of thestaple fiber ends may protrude into the tuft 6, depending upon suchthings as the number of staple fibers in the web, the staple fiber cutlength, and the height of the tufts. In some instances, it may bedesired to use a blend of fibers of different lengths in a precursor webor fibers of different lengths in different layers. This may be able toselectively separate the longer fibers from the shorter fibers. Thelonger fibers may predominately form the tuft 6 while the shorter fiberspredominately remain in the portion of the web not forming the tuft 6. Amixture of fiber lengths can include fibers of approximately 2 to 8centimeters for the longer fibers and less than about 1 centimeter forthe shorter fibers.

First precursor web 20 can be a fibrous woven or nonwoven web comprisingelastic or elastomeric fibers. Elastic or elastomeric fibers can bestretched at least about 50% and return to within 10% of their originaldimension. Tufts 6 can be formed from elastic fibers if the fibers aresimply displaced due to the mobility of the fiber within the nonwoven,or if the fibers are stretched beyond their elastic limit and areplastically deformed.

Second precursor web 21 can be a polymer film web have sufficientintegrity to be formed into the laminate by the process described below,and that it have sufficiently less elongation properties relative tofirst precursor web 20, such that upon experiencing the strain of fibersfrom first precursor web 20 being urged out-of-plane in the direction ofsecond precursor web 21, second precursor web 21 will rupture, e.g., bytearing due to extensional failure, such that portions of firstprecursor web 20 can extend through, (i.e., “punch through” so tospeak), the plane of the first surface 13 of second precursor web 21 toform tufts 6 on first side 3 of web 1 and a cap 7 will remain over thedistal portion 31 of each tuft 6.

The second precursor web 21 can be microtextured polymer film. Bymicrotextured it is meant that there are a plurality of microfeatures inthe second precursor web 21 between the tufts 6, such microfeaturesbeing sized and dimensioned so that a plurality of microfeatures can fitbetween adjacent tufts 6. That is, the micro features are sized anddimensioned such that the microfeatures can have a maximum dimensionsmaller than one-half the distance between adjacent tufts 6. Themicrofeatures can, for example, be microapertures or micro bubbles,examples of which are disclosed in U.S. Pat. No. 7,402,732, issued toStone et al. and U.S. Pat. No. 4,839,216 issued to Curro et al., U.S.Pat. No. 4,609,518 issued to Curro et al., and U.S. Pat. No. 4,609,518issued to Curro et al. The polymer film can be an apertured polymerfilm, the apertures of which each have an area of between about 0.01 mm²and about 0.78 mm². The microfeatures can be raised portions. Raisedportions can be integral extensions of the polymer film or can bematerials added to the surface of the polymer film.

As shown in FIG. 2 or 3, tuft 6 can comprise a plurality of loopedfibers 8 that are substantially aligned such that tuft 6 has a distinctlinear orientation and a longitudinal axis L. Tuft 6 can also have atransverse axis T generally orthogonal to longitudinal axis L in theMD-CD plane. In the embodiment shown in FIGS. 1 and 2, longitudinal axisL is parallel to the MD. In one embodiment, the spaced apart tufts 6have generally parallel longitudinal axes L. The number of tufts 6 perunit area of web 1, i.e., the area density of tufts 6, can be variedfrom 1 tuft per unit area, e.g., square centimeter to as high as 100tufts per square centimeter. There can be at least 10, or at least 20tufts 6 per square centimeter, depending on the end use. In general, thearea density need not be uniform across the entire area of web 1, buttufts 6 can be only in certain regions of web 1, such as in regionshaving predetermined shapes, such as lines, stripes, bands, circles, andthe like. Tufts 6 can be spaced sufficiently closely so as toeffectively cover first side 3 of web 1.

As can be appreciated by the description herein, in many embodiments ofweb 1 openings 4 of second precursor web 21 can have a distinct linearorientation and a longitudinal axis, which is oriented parallel to thelongitudinal axis L of its corresponding tuft 6. Likewise, openings 4will also have a transverse axis generally orthogonal to longitudinalaxis in the MD-CD plane.

As shown in FIGS. 1-4, tufts 6 extend above openings 4 in secondprecursor web 21. Openings 4 are formed by locally rupturing secondprecursor web 21 by the process described in detail below. Rupture mayinvolve a simple splitting open of second precursor web 21 such that aportion or portions of second precursor web 21 can be deflected or urgedout-of-plane (i.e., the plane of second precursor web 21) to form capstructures, referred to herein as cap, or caps, 7. The form andstructure of caps 7 may be dependent upon the material properties ofsecond precursor web 21. Caps 7 can have the general structure of one ormore caps 7, as shown in FIGS. 1 and 2.

Tufts 6 are, in a sense, “punched above” second precursor web 21 and canbe “locked” in place by frictional engagement with openings 4. In someembodiments, for example, the lateral width of opening 4 (i.e., thedimension measured parallel to its transverse axis) can be less than themaximum width of the tooth that formed the opening (per the processdescribed below). This indicates a certain amount of recovery at theopening that tends to constrain tuft 6 from pulling back out throughopening 4. The frictional engagement of the tufts and openings providesfor a laminate web structure having permanent tufting on one side thatcan be formed without adhesives or thermal bonding.

As shown in FIGS. 1-4, one characteristic of tufts 6 can be thepredominant directional alignment of the fibers 8 or 18. For example,looped, aligned fibers 8 can be described as having a significant ormajor vector component parallel to the Z-CD plane and the looped fibers8 have a substantially uniform alignment with respect to transverse axisT when viewed in plan view, such as in FIG. 4. By “looped” fibers 8 ismeant fibers 8 that are integral with and begin and end in firstprecursor web 20 but extend outwardly in the Z-direction from firstsurface 13 of second precursor web 21. By “aligned” with respect tolooped fibers 8 of tufts 6 is meant that looped fibers 8 are allgenerally oriented such that, if viewed in plan view as in FIG. 4, eachof the looped fibers 8 has a significant vector component parallel tothe transverse axis T, and can have a major vector component parallel tothe transverse axis T.

In contrast, non-looped fibers 18 are integral with, but only begin infirst precursor web 20 and have a free end extending outwardly in theZ-direction from first surface 13 of second precursor web 21. Non-loopedfibers 18 can also have a generally uniform alignment described ashaving a significant or major vector component parallel to the Z-CDplane.

For both looped fibers 8 and non-looped fibers 18, the alignment can bea characteristic of tufts 6 prior to any post-manufacture deformationdue to winding onto a roll, or compression in use in an article ofmanufacture.

As used herein, a looped fiber 8 oriented at an angle of greater than 45degrees from the longitudinal axis L when viewed in plan view, as inFIG. 4, has a significant vector component parallel to the transverseaxis T. As used herein, a looped fiber 8 oriented at an angle of greaterthan 60 degrees from longitudinal axis L when viewed in plan view, as inFIG. 4, has a major vector component parallel to the transverse axis T.In some embodiments, at least 50%, at least 70%, and at least 90% offibers 8 of tuft 6 have a significant or a major vector componentparallel to transverse axis T. Fiber orientation can be determined byuse of magnifying means if necessary, such as a microscope fitted with asuitable measurement scale. In general, for a non-linear segment offiber viewed in plan view, a straight-line approximation for bothlongitudinal axis L and the looped fibers 8 can be used for determiningthe angle of looped fibers 8 from longitudinal axis L. For example, asshown in FIG. 4, one fiber 8 a is shown emphasized by a heavy line, andits linear approximation 8 b is shown as a dashed line. This fiber makesan angle of approximately 80 degrees with the longitudinal axis(measured counterclockwise from L).

The orientation of looped fibers 8 in the tufts 6 is to be contrastedwith the fiber composition and orientation for first precursor web 20,which, for nonwoven webs can be described as having a substantiallyrandomly-oriented fiber alignment.

In the embodiment shown in FIG. 1 the longitudinal axes L of tufts 6 aregenerally aligned in the MD. Tufts 6 and, therefore, longitudinal axesL, can, in principle, be aligned in any orientation with respect to theMD or CD. Therefore, in general, it can be said that for each tuft 6,the looped aligned fibers 8 are aligned generally orthogonal to thelongitudinal axis L such that they have a significant vector componentparallel to transverse axis T, and can have a major vector componentparallel to transverse axis T.

In some embodiments, as described below, another characteristic of tufts6 comprising predominantly looped, aligned fibers 8, can be theirgenerally open structure characterized by open void area 10 definedinteriorly of tufts 6, as shown in FIGS. 2 and 3. The void area 10 mayhave a shape that is wider or larger at the distal portion 31 of thetuft 6 and narrower at the tuft base 17 of the tuft 6. This is oppositeto the shape of the tooth which is used to form the tuft 6. By “voidarea” is not meant an area completely free of any fibers; the term ismeant as a general description of the general appearance of tufts 6.Therefore, it may be that in some tufts 6 a non-looped fiber 18 or aplurality of loose non-looped fibers 18 may be present in the void area10. By “open” void area is meant that the two longitudinal ends of tuft6 are generally open and free of fibers, such that tuft 6 can formsomething like a “tunnel” structure in an uncompressed state, as shownin FIG. 3.

Additionally, as a consequence of a method of making web 1, the secondside 5 of web 1 exhibits discontinuities 16 characterized by a generallylinear indentation defined by formerly random fibers of the secondsurface 14 of first precursor web 20 having been urged directionally(i.e., in the “Z -direction” generally orthogonal to the MD-CD plane asshown in FIGS. 1 and 3) into tufts 6 by the teeth of the formingstructure, described in detail below. The abrupt change of orientationexhibited by the previously randomly-oriented fibers of first precursorweb 20 defines the discontinuity 16, which exhibits a linearity suchthat it can be described as having a longitudinal axis generallyparallel to longitudinal axis L of the tuft 6. Due to the nature of manynonwoven webs useful as first precursor webs 20, discontinuity 16 maynot be as distinctly noticeable as tufts 6. For this reason, thediscontinuities 16 on the second side 5 of web 1 can go unnoticed andmay be generally undetected unless web 1 is closely inspected. As such,the second side 5 of web 1 can have the look and feel of an un-tuftedfirst precursor web 20. Thus in some embodiments, web 1 can have thetextured look and feel of terry cloth on first side 3, and a relativelysmooth, soft look and feel on second side 5. In other embodiments,discontinuities 16 can appear as apertures, and may be apertures throughweb 1 via the ends of the tunnel-like tufts 6.

From the description of web 1 comprising a nonwoven first precursor web20, it can be seen that the fibers 8 or 18 of tuft 6 can originate andextend from either the first surface 12 or the second surface 14 offirst precursor web 20. Of course the fibers 8 or 18 of tuft 6 can alsoextend from the interior 28 of first precursor web 20. As shown in FIG.3, the fibers 8 or 18 of tufts 6 extend due to having been urged out ofthe generally two-dimensional plane of first precursor web 20 (i.e.,urged in the “Z -direction” as shown in FIG. 3). In general, the fibers8 or 18 of the tufts 6 comprise fibers that are integral with and extendfrom the fibers of the first precursor web 20.

Therefore, from the above description, it is understood that in oneembodiment web 1 can be described as being as a laminate web comprisinga nonwoven web in facing relationship with a polymer film, the laminateweb comprising a first side comprising the polymer film and a pluralityof discrete tufts comprising fibers integral with and extending from thenonwoven web, wherein each of the tufts has a tuft base proximal to thenonwoven web and a distal portion opposing the tuft base, wherein atleast part of the distal portion of each of the tufts is covered by acap, each cap being an integral extension of the polymer film extendingover the distal portion of a discrete tuft, the cap comprising a firstopening comprising a location of rupture in the polymer film above whichthe tuft extends.

The extension of fibers 8 or 18 can be accompanied by a generalreduction in fiber cross sectional dimension (e.g., diameter for roundfibers) due to plastic deformation of the fibers and Poisson's ratioeffects. Therefore, the aligned looped fibers 8 of tuft 6 can have atuft average fiber diameter less than the nonwoven web average fiberdiameter of the fibers of first precursor web 20. That is, portions ofthe fibers comprising the tufts 6 can have a fiber diameter less than11280 13 the nonwoven web fiber diameter. It is believed that thisreduction in fiber diameter contributes to the perceived softness of thefirst side 3 of web 1, a softness that can be comparable to cotton terrycloth, depending on the material properties of the first precursor web20. It has been found that the reduction in fiber cross-sectionaldimension is greatest intermediate the tuft base 17 and the distalportion 31 of tuft 6. This is believed to be due to the method ofmaking, as disclosed below. As shown on FIG. 3, it is believed thatportions of fibers at the tuft base 17 and distal portion 31 of tufts 6are adjacent the tip of teeth 110 of roll 104, described more fullybelow, and are frictionally locked and immobile during processing. Thus,the intermediate portions of tufts 6 are more free to stretch, orelongate, and accordingly, can experience a corresponding fiber crosssectional dimension reduction. The first precursor web 20 may laterallysqueeze the tuft base 17 of the tuft 6. The tuft base 17 of the tuft 6may even be closed (if the fibers from the tuft 6 are close enoughtogether to touch) or may remain open. Generally, any opening at thetuft base 17 is narrow. The closing or narrowing or squeezing of otherfibers at the tuft base 17 can help to stabilize the tufts 6.

Caps 7 are integral extensions of the second precursor web 21, which isa polymer film. At least part of a distal portion 31 of each of thetufts 6 is covered by a cap 7. As shown in FIGS. 1-4, a cap 7 can be atunnel shaped cap 7 having a first opening 51 and a second opening 52.The first opening 51 comprises a location of rupture 53 in the secondprecursor web and the tuft 6 extends above the location of rupture 53.The caps 7 integrally extend from the second precursor web 21 proximalthe location of rupture 53. The location of rupture 53 may be a point ora line. A cap 7 is formed by rupturing the second precursor web 21 at atleast one location of rupture 53 and stretching the polymer film out ofplane of the first surface 13 of the second precursor web 21 to form anopening such as first opening 51 or a first opening 51 and a secondopening 52. The location of rupture 53 can define at least part of theboundary of the opening 4. The remainder of the opening 4 can be definedby one or more additional locations of rupture or portions of the cap 7proximal the location from which the cap 7 integrally extends from thesecond precursor web 21. The second precursor web 21 can be fluidimpervious in absence of a rupture 53.

The first opening 51 can be arch shaped such that the first opening 51is broadest proximal the first surface 13 of the second precursor web 21and generally becomes narrower towards the portion of the cap coveringthe distal portion 31 of the tuft 6. The cap 7 can have a cap base 71proximal the first surface 13 of the second precursor web 21. The capbase 71 can be narrower than a portion of the cap 7 away from the capbase 71. That is, the distance between the extension locations 54 can beless than maximum lateral extent of the cap 7 away (i.e. above) from thecap base 71. The first opening 51 can be uppercase omega shaped (Ω) suchthe first opening 51 is narrower proximal the first surface 13 of thesecond precursor web 21 than at a location midway between the tuft base17 and the distal portion 31 of tuft 6. Similarly, if a second opening52 is present, second opening 52 can be arch shaped such that the secondopening 52 is broadest proximal the first surface 13 of the secondprecursor web 21 and generally narrows towards the portion of the cap 7covering the distal portion 31 of the tuft 6. The second opening 52 canbe uppercase omega shaped (Ω) such that the second opening 52 isnarrower proximal the first surface 13 of the second precursor web 21than at a location midway between the tuft base 17 and the distalportion 31 of tuft 6. The second opening 52 can oppose the first opening51 in that at least part of the tuft 6 is between second opening 52 andfirst opening 51. The first opening 51, the second opening 52, and anyadditional openings can make the laminate web 1 liquid pervious.

If there is a first opening 51 and a second opening 52, the cap 7 canintegrally extend from the second precursor web 21 at at least twoextension locations 54 spaced apart from one another by the firstopening 51 and second opening 52. The at least two extension locations54 can be at opposing positions on opposing sides of the tuft 6. The cap7 can integrally extend from the second precursor web 21 (polymer film)at at least two extension locations 54, each extension location 54adjacent a location of rupture 53. In addition to a first opening 51 anda second opening 52, there can be additional openings. For instance, ifthere are three or more openings (e.g., first opening 51, second opening52, and third opening), the cap 7 can integrally extend from the secondprecursor web 21 at at least three extension locations 54 spaced apartfrom one another by the openings (e.g. first opening 51, second opening52, and third opening).

As shown in FIG. 5, cap 7 can have length 61 and a width 62. The length61 of cap 7 is taken to be between the first opening 51 and secondopening 52. Cap 7 can also have a width 62 taken to be the maximumdimension of the cap 7 as measured orthogonal to the length 61 of thecap 7. The plane aspect ratio of the cap 7 can be defined as the ratiobetween the length 61 and the width 62 of cap 7. The aspect ratio of thecap 7 can be greater than about 0.5. The aspect ratio of the cap 7 canbe greater than about 1. The aspect ratio of the cap 7 can be greaterthan about 1.5. The aspect ratio of the cap 7 can be greater than about2. In general, it is thought that caps 7 having a higher aspect ratiocan be more noticeable to an observer of the laminate web 1 and mightalso better resist fluid flow along the surface of web 1 in a directionorthogonal to the longitudinal axis L of the tuft 6.

Caps 7 in laminate web 1 are thought to mask or partially mask fluidthat is collected by the laminate web 1 and remains in the capillariesbetween fibers 8 forming tuft 6. Such a laminate web employed in anabsorbent article such as a wipe, a sanitary napkin, a tampon, or adiaper can be appealing to the user (or caregiver) in that potentiallyunsightly urine, menses, feces, or other liquid retained in thecapillaries between fibers 8 forming tuft 6 will be obscured orpartially obscured from the viewer. In an absorbent article such as asanitary napkin, in absence of the caps 7, tufts 6 can essentially havethe color of menses, which might be unattractive to the user of thesanitary napkin. The caps cover or partially cover tufts in which mensesis held and can make the laminate web 1 appear less red or even allowthe laminate web 1 to maintain its virgin color (e.g. prior to insult bya fluid).

If the second precursor web 21 and cap 7 extending there from is apolymer film comprising a whitener, such as titanium dioxide, the caps 7can be more effective at obscuring materials held in the capillaries ofthe tufts 6 from view. Such caps 7 can better maintain a perceived colorof white, which many consumers associate with cleanliness.

The caps 7 can have an opacity greater than about 10%, greater thanabout 20%, greater than about 30%, greater than about 40%, greater thanabout 50%, greater than about 60%, greater than about 70%, greater thanabout 80%, or greater than about 90%. The cap can be opaque. The secondprecursor web can have an opacity. The opacity of the caps 7 can be lessthan the opacity of the second precursor web 21 from which the caps 7extend, for instance as a result of stretching of the precursor web 21to form cap 7. The caps 7 can have an opacity that is between about 80%and about 95% of the opacity of the second precursor web. The caps 7 canhave an opacity that is between about 50% and about 95% of the opacityof the second precursor web. The caps can have an opacity that isbetween about 35% and about 95% of the opacity of the second precursorweb. The greater the opacity of the caps 7, the more effective the caps7 might be at obscuring liquids that held in the capillaries of thetufts 6. The caps 7 can have an opacity less than about 90% of theopacity of the second precursor web 21. The caps 7 can have an opacityless than about 75% of the opacity of the second precursor web 21. Thecaps 7 can have an opacity less than about 50% of the opacity of thesecond precursor web 21.

Second precursor web 21 can have a polymer film thickness t and the cap7 can have a cap thickness tc. Being that the caps 7 are integralextensions of the second precursor web 21 and formed by stretching thepolymer film out of plane of the first surface 13 of the secondprecursor web 21, the cap thickness tc of a portion of the cap 7 can beless than the polymer film thickness t. That is, the polymer film thatis extended to form a cap 7 is thinned at at least some portion of thecap 7 relative to the planar portion of the polymer film from which thecap 7 extends. The cap thickness tc may not be uniform about the entirefirst opening 51 and/or second opening 52. The cap thickness tc at adistal portion of the cap 7 may be the same or less than the polymerfilm thickness t. The cap thickness tc at a distal portion of the cap 7may be about the same or less than the polymer film thickness t and thecap thickness tc at a portion of the cap 7 between the distal portion ofthe cap 7 and the polymer film may be less than the polymer filmthickness t. Thinning of the cap 7 may provide for caps 7 having a softhand. Further, because the cap 7 might be thin and might readily bedeformed, the characteristics of the tuft 6 underlying the cap 7 mightgovern the tactile impression imparted by the tuft 6 having a cap 7.Therefore, the characteristics of the tuft 6 can be important to thetactile impression imparted by the laminate web 1.

Referring to FIG. 6 there is shown an apparatus and method for makingweb 1 of the present invention. The apparatus 100 comprises a pair ofintermeshing rolls 102 and 104, each rotating about an axis A, the axesA being parallel in the same plane. Roll 102 comprises a plurality ofridges 106 and corresponding grooves 108 which extend unbroken about theentire circumference of roll 102. Roll 104 is similar to roll 102, butrather than having ridges that extend unbroken about the entirecircumference, roll 104 comprises a plurality of rows ofcircumferentially-extending ridges that have been modified to be rows ofcircumferentially-spaced teeth 110 that extend in spaced relationshipabout at least a portion of roll 104. The individual rows of teeth 110of roll 104 are separated by corresponding grooves 112. In operation,rolls 102 and 104 intermesh such that the ridges 106 of roll 102 extendinto the grooves 112 of roll 104 and the teeth 110 of roll 104 extendinto the grooves 108 of roll 102. The intermeshing is shown in greaterdetail in the cross sectional representation of FIG. 7, discussed below.Both or either of rolls 102 and 104 can be heated by means known in theart such as by using hot oil filled rollers or electrically-heatedrollers.

In FIG. 6, the apparatus 100 is shown in a configuration having onepatterned roll, e.g., roll 104, and one non-patterned grooved roll 102.However, in certain embodiments it may be preferable to use twopatterned rolls 104 having either the same or differing patterns, in thesame or different corresponding regions of the respective rolls. Such anapparatus can produce webs with tufts 6 protruding from both sides ofthe web 1.

The method of making a web 1 of the present invention in a continuousprocess is depicted in FIG. 6. Web 1 can be made by mechanicallydeforming precursor webs, such as first and second precursor webs, 20and 21 that can each be described as generally planar and twodimensional prior to processing by the apparatus shown in FIG. 5. By“planar” and “two dimensional” is meant simply that the webs start theprocess in a generally flat condition relative to the finished web 1that has distinct, out-of-plane, Z-direction three-dimensionality due tothe formation of tufts 6. “Planar” and “two-dimensional” are not meantto imply any particular flatness, smoothness or dimensionality.

The process and apparatus of the present invention is similar in manyrespects to a process described in U.S. Pat. No. 5,518,801 entitled “WebMaterials Exhibiting Elastic-Like Behavior” and referred to insubsequent patent literature as “SELF” webs, which stands for“Structural Elastic-like Film”. However, there are significantdifferences between the apparatus and process of the present inventionand the apparatus and process disclosed in the '801 patent, and thedifferences are apparent in the respective webs produced thereby. Asdescribed below, the teeth 110 of roll 104 have a specific geometryassociated with the leading and trailing edges that permit the teeth toessentially “punch” through the precursor webs 20, 21 as opposed to, inessence, deforming the web. In a two layer laminate web 1 the teeth 110urge fibers from a first precursor web 20 simultaneously out-of-planeand through second precursor web 21, which is ruptured, so to speak, bythe teeth 110 pushing the fibers 8 through the plane of second precursorweb 21 to form tufts 6 and caps 7 Therefore, a web 1 of the presentinvention can have tufts 6 of non-looped fibers 18 and/or “tunnel-like”tufts 6 of looped, aligned fibers 8 extending through and away from thesurface 13 of a first side 3, unlike the “tent-like” rib-like elementsof SELF webs which each have continuous side walls associated therewith,i.e., a continuous “transition zone,” and which do not exhibit rupturingof second precursor web 21.

Precursor webs 20 and 21 are provided either directly from theirrespective web making processes or indirectly from supply rolls andmoved in the machine direction to the nip 116 of counter-rotatingintermeshing rolls 102 and 104. The precursor webs are preferably heldin a sufficient web tension so as to enter the nip 116 in a generallyflattened condition by means well known in the art of web handling. Aseach precursor web 20, 21 goes through the nip 116 the teeth 110 of roll104 which are intermeshed with grooves 108 of roll 102 simultaneouslyurge portions of first precursor web 20 out of the plane of firstprecursor web 20 and through the plane of second precursor web 21 toform tufts 6. In effect, teeth 110 “push” or “punch” fibers of firstprecursor web 20 through the plane of second precursor web 21.

As the tip of teeth 110 push through first and second precursor webs 20,21 the portions of the fibers of first precursor web 20 that areoriented predominantly in the CD across teeth 110 are urged by the teeth110 out of the plane of first precursor web 20. Fibers can be urged outof plane due to fiber mobility, or they can be urged out of plane bybeing stretched and/or plastically deformed in the Z-direction. Portionsof first precursor web 20 urged out of plane by teeth 110 push throughthe plane of the first surface 13 of second precursor web 21, which dueto its relatively lower extensibility, ruptures, thereby resulting information of caps 7 and tufts 6 on first side 3 of web 1. Fibers offirst precursor web 20 that are predominantly oriented generallyparallel to the longitudinal axis L, i.e., in the MD of precursor web 20as shown in FIG. 1, are simply spread apart by teeth 110 and remainsubstantially in their original, randomly-oriented condition. This iswhy the looped fibers 8 can exhibit the unique fiber orientation inembodiments such as the one shown in FIGS. 1-4, which is a highpercentage of fibers of each tuft 6 having a significant or major vectorcomponent parallel to the transverse axis T of tuft 6.

It can be appreciated by the forgoing description that when web 1 ismade by the apparatus and method of the present invention that theprecursor webs 20, 21 should possess differing material properties withrespect to the ability of the precursor webs to elongate before failure,e.g., failure due to tensile stresses. In particular, a nonwoven firstprecursor web 20 can have greater fiber mobility and/or greater fiberelongation characteristics relative to second precursor web 21, suchthat the fibers thereof can move or stretch sufficiently to form tufts 6while the second precursor web 21 ruptures, i.e., does not stretch tothe extent necessary to form tufts.

The degree to which the fibers of nonwoven precursor webs are able toextend out of plane without plastic deformation can depend upon thedegree of inter-fiber bonding of the precursor web. For example, if thefibers of a nonwoven precursor web are only very loosely entangled toeach other, they will be more able to slip by each other and thereforebe more easily extended out of plane to form tufts. On the other hand,fibers of a nonwoven precursor web that are more strongly bonded, forexample by high levels of thermal point bonding, hydroentanglement, orthe like, will more likely require greater degrees of plasticdeformation in extended out-of-plane tufts. Therefore, in oneembodiment, first precursor web 20 can be a nonwoven web havingrelatively low inter-fiber bonding.

For a given maximum strain (e.g., the strain imposed by teeth 110 ofapparatus 100), second precursor web 21 must actually fail under thetensile loading produced by the imposed strain to locally (i.e., in thearea of strain) fail in tension, thereby producing openings 4 throughwhich tufts 6 can extend. If second precursor web 21 merely deforms orstretches in the region of induced strain, but does not actually fail,thereby producing an opening 4 therein, a tuft 6 may not result. In oneembodiment second precursor web 21 has an elongation to break in therange of 1%-5%. While the actual required elongation to break depends onthe strain to be induced to form web 1, it is recognized that for mostembodiments, second precursor web 21 can exhibit a webelongation-to-break of 6%, 7%, 8%, 9%, 10%, or more. It is alsorecognized that actual elongation-to-break can depend on the strainrate, which, for the apparatus shown in FIG. 6 is a function of linespeed. Elongation to break of webs used in the present invention can bemeasured by means known in the art, such as by standard tensile testingmethods using standard tensile testing apparatuses, such as thosemanufactured by Instron, MTS, Thwing-Albert, and the like.

Furthermore, relative to first precursor web 20, second precursor web 21can have lower elongation-to-break (i.e., elongation-to-break of thefilm) such that, rather than extending out-of-plane to the extent of thetufts 6, second precursor web 21 ruptures in tension under the strainproduced by the formation of tufts 6, e.g., by the teeth 110 ofapparatus 100. In general, second precursor web 21 can have anelongation to break of at least 10% less than the first precursor web20, at least 30% less, more preferably at least 50% less, and even morepreferably at least about 100% less than that of first precursor web 20.Relative elongation to break values of webs used in the presentinvention can be measured by means known in the art, such as by standardtensile testing methods using standard tensile testing apparatuses, suchas those manufactured by Instron, MTS, Thwing-Albert, and the like.

The number, spacing, and size of tufts 6 can be varied by changing thenumber, spacing, and size of teeth 110 and making correspondingdimensional changes as necessary to roll 104 and/or roll 102. Thisvariation, together with the variation possible in precursor webs 20, 21permits many varied webs 1 to be made for many purposes. For example, aweb 1 made from a first precursor web 20 comprising a relatively lowbasis weight nonwoven web of plastically-extensible spunbond polymerfibers and a second precursor web 21 comprising relativelylow-extensible synthetic polymer film could be could be used as a terrycloth-like fabric for semi-durable or durable clothing, or for personalcare items as are described in WO 01/76523. As described more fullybelow, a web 1 comprising a nonwoven/film first precursor web/secondprecursor web combination can also be used as a component in disposableabsorbent articles.

FIG. 7 shows in cross section a portion of the intermeshing rolls 102and 104 and ridges 106 and teeth 1 10. As shown teeth 110 have a toothheight TH (note that TH can also be applied to ridge height; in oneembodiment tooth height and ridge height are equal), and atooth-to-tooth spacing (or ridge-to-ridge spacing) referred to as thepitch P. As shown, depth of engagement E is a measure of the level ofintermeshing of rolls 102 and 104 and is measured from tip of ridge 106to tip of tooth 110. The depth of engagement E, tooth height TH, andpitch P can be varied as desired depending on the properties ofprecursor webs 20, 21 and the desired characteristics of web 1. Forexample, in general, the greater the level of engagement E, the greaterthe necessary elongation or fiber-to-fiber mobility characteristics thefibers of first precursor web 20 must possess. Also, the greater thedensity of tufts 6 desired (tufts 6 per unit area of web 1), the smallerthe pitch should be, and the smaller the tooth length TL and toothdistance TD should be, as described below.

FIG. 8 shows one embodiment of a roll 104 having a plurality of teeth110 useful for making a terry cloth-like web 1 from a nonwoven firstprecursor web 20 having a basis weight of between about 60 gsm and 100gsm, or about 80 gsm and a polyolefin film (e.g., polyethylene orpolypropylene) second precursor web 21 having a density of about0.91-0.94 and a basis weight of about 20 gsm.

An enlarged view of teeth 110 is shown in FIG. 9. In this embodiment ofroll 104 teeth 110 have a uniform circumferential length dimension TLmeasured generally from the leading edge LE to the trailing edge TE atthe tooth tip 111 of about 1.25 mm and are uniformly spaced from oneanother circumferentially by a distance TD of about 1.5 mm. For making aterry-cloth web 1 from web 1 having a total basis weight in the range ofabout 60 to about 100 gsm, teeth 110 of roll 104 can have a length TLranging from about 0.5 mm to about 3 mm and a spacing TD from about 0.5mm to about 3 mm, a tooth height TH ranging from about 0.5 mm to about 5mm, and a pitch P between about 1 mm (0.040 inches) and about 5 mm(0.200 inches). Depth of engagement E can be from about 0.5 mm to about5 mm (up to a maximum equal to tooth height TH). Of course, E, P, TH, TDand TL can be varied independently of each other to achieve a desiredsize, spacing, and area density of tufts 6 (number of tufts 6 per unitarea of web 1).

As shown in FIG. 9, each tooth 110 has a tip 111, a leading edge LE anda trailing edge TE. The tooth tip 111 is elongated and has a generallylongitudinal orientation, corresponding to the longitudinal axes L oftufts 6 and discontinuities 16. It is believed that to get the tufted,looped tufts 6 of the web 1 that can be described as being terrycloth-like, the LE and TE should be very nearly orthogonal to the localperipheral surface 120 of roll 104. As well, the transition from the tip111 and LE or TE should be a sharp angle, such as a right angle, havinga sufficiently small radius of curvature such that teeth 110 pushthrough second precursor web 21 at the LE and TE. Without being bound bytheory, it is believed that having relatively sharply angled tiptransitions between the tip of tooth 110 and the LE and TE permits theteeth 110 to punch through precursor web 20 and rupture precursor web 21“cleanly”, that is, locally and distinctly. Further, a sharp transitionmay provide for formation of the first opening 51 and second opening 52.For polymer film having microtexture such as micro apertures,microbubbles, or other such relatively small structures in the polymerfilm (relative to the spacing between tufts 6), stress concentrations inthe polymer film arising as a result of the microtexture might providefor formation of caps 7, as opposed to having the tuft erupt through thepolymer film without formation of a caps 7. When so processed, the web 1is not imparted with any particular elasticity, beyond what theprecursor webs 20 and 21 may have possessed originally.

Therefore, from the above description, it is understood that in oneembodiment web 1 can be described as being a laminate web formed byselective mechanical deformation of at least a first and secondprecursor webs, the first precursor web being a nonwoven web and thesecond precursor web being a polymer film, the laminate web having afirst side, the first side comprising the second precursor web and aplurality of discrete tufts comprising fibers integral with andextending from the nonwoven web, each of the tufts having a tuft baseproximal to the nonwoven web and a distal portion opposing the tuftbase, at least part of the distal portion of each of the tufts iscovered by cap, each cap being an integral extension of the polymer filmextending over the distal portion of a discrete tuft, the cap comprisinga first opening comprising a location of rupture in the polymer filmabove which the tuft extends.

While not wishing to be bound by theory, it is believed that if thefibers of the first precursor web have a highly curvilinear shape, e.g.,curled fibers, the resultant tufts 6 will have more looped fibers 8 andless non-looped fibers 18 as compared to more linear fiberconformations. It is believed that such fiber conformations have alesser chance of bridging between two adjacent teeth, and, as a resultthey are less prone to be stretched beyond their breaking point, andthus have a greater chance of forming complete loop structures.Furthermore, such curvilinear-shaped fibers can be made by usingeccentric bicomponent fibers, or side-by-side bicomponent fibers, suchas bicomponent fibers consisting of polyethylene and nylon.

It has been found that certain nonwoven webs, such as carded webscomprising staple-length fibers, when used as first precursor web 20produce very few looped fibers 8 in tufts 6, so that the tufts 6produced in these webs cannot be described as comprising a plurality oflooped, aligned fibers 8 as described above with respect to FIGS. 1-4.Instead, carded nonwoven webs can produce tufts 6 having few, if any,looped, aligned fibers 8, and many, if not all, non-aligned fibersand/or non-looped fibers 18. It is believed that the non-alignment offibers in tufts 6 made from carded webs is due in part to the nature ofthe fiber content of carded webs. Staple fibers are not “endless,” butinstead have a predetermined length on the order of about 15 mm to about100 mm, and, more typically from about 40 mm to about 80 mm. Therefore,when a carded web is processed by the apparatus described with respectto FIG. 6, it is believed that there is a much greater likelihood that aloose fiber end will be in the vicinity of a tuft 6 and thus produce anon-looped fiber end in tuft 6. Furthermore, often staple fibers do nothave the same elongation characteristics of spunbond or meltblownfibers, for example. However, even if tufts 6 have no looped fibers, thefibrous tufts can nevertheless provide a softness benefit and produce aweb having terry cloth-like characteristics.

If a woven first precursor web 20 is utilized, the formation andstructure of tufts 6 can be very close to the same as that exhibited bytufts 6 formed from nonwoven webs. For example, if a woven firstprecursor web 20 has extensible warp and/or weft threads predominantlyoriented in a cross machine direction, upon being processed by theapparatus 100 described above, the teeth 110 tend to separate themachine direction threads (either warp or weft) and only urge out ofplane the cross-machine direction threads. Thus, the web 1 produced froma woven first precursor web 20 can look and feel very much like terrycloth fabric.

In some embodiments, first precursor web 20 is a nonwoven web in whichthere are minimal fiber-to-fiber bonds. For example, the precursor webcan be a nonwoven web having a pattern of discrete thermal point bonds,as is commonly known in the art for nonwoven webs. In general, however,it is desirable to minimize the number of bond points and maximize thespacing so as to allow for maximum fiber mobility and dislocation duringformation of tufts 6. In general, using fibers having relatively highdiameters, and/or relatively high extension to break, and/or relativelyhigh fiber mobility, might result in better and more distinctly formedtufts 6.

Although web 1 is disclosed as a two layer web made from two precursorwebs, it is not necessary that it be limited to two layers. For example,a three-layer or more laminate can be made from three precursor webs.For example, web 1 could comprise the top sheet, secondary topsheet, andcore of hygiene products. In general, it is not necessary that adhesiveor other bonding means be utilized to make laminate web 1.

The constituent layers of web 1 (e.g., precursor webs 20 and 21 and anyother layers) can be held in a face-to-face laminated relationship byvirtue of the “locking” effect of the tufts 6 that extend throughopenings 4 in second precursor web 21. In some embodiments it may bedesirable to use adhesives or thermal bonding or other bonding means,depending on the end use application of web 1. For example, a web 1comprising bicomponent fiber nonwoven webs can be through-air bondedafter formation of tufts 6 to provide for layer-to-layer adhesion forgreater peel strength. Additionally, it may be desirable to applyadhesive to at least a portion of one of the precursor webs. Forexample, in some embodiments adhesive, chemical bonding, resin or powderbonding, or thermal bonding between layers can be selectively applied tocertain regions or all of the precursor webs. In the case of adhesiveapplication, for example, adhesive can be applied in a continuousmanner, such as by slot coating, or in a discontinuous manner, such asby spraying, extruding, and the like. Discontinuous application ofadhesive can be in the form of stripes, bands, droplets, and the like.

In a multilayer web 1 each precursor web can have different materialproperties, thereby providing web 1 with beneficial properties. Forexample, web 1 comprising two (or more) precursor webs, e.g., first andsecond precursor webs, can have beneficial fluid handling properties foruse as a topsheet on a disposable absorbent article, as described below.For superior fluid handling, for example, first precursor web 20 can becomprised of relatively hydrophilic fibers. Second precursor web 21 canbe polymer film, e.g., a polyethylene film, and can be hydrophobic orrendered hydrophobic. Fluid deposited upon the upper relativelyhydrophobic polymer film might be quickly acquired by hydrophilic tufts6.

One driving mechanism for rapid fluid transport might be the capillarystructures formed by the generally aligned fibers 8, 18 of tufts 6. Thefibers 8, 18 form directionally-aligned capillaries between adjacentfibers, and the capillary action is enhanced by the general convergenceof fibers near the base 17 of tufts 6.

It is believed that the rapid fluid transport might further be increaseddue to the ability of fluid to enter the web 1 via the voids 10 definedby looped tufts 6. This “lateral entry” capability and/or capillaryaction, and/or the hydrophilicity gradient afforded by the structure ofweb 1 might make web 1 an ideal material for optimal fluid handling fordisposable absorbent articles.

Depending on the precursor webs 20 and 21 utilized and the dimensionalparameters of rolls 102 and, including teeth 110, web 1 can exhibit awide range of physical properties. The web 1 can exhibit a range oftexture subjectively experienced as ranging from softness to roughness,an absorbency ranging from non-absorbent to very absorbent, a bulkinessranging from relatively low bulk to relatively high bulk; a tearstrength ranging from low tear strength to high tear strength; anelasticity ranging from non-elastic to at least 100% elasticallyextensible, a chemical resistance ranging from relatively low resistanceto high resistance, depending on the chemical considered, and many othervariable parameters generally described as shielding performance, alkaliresistance, opacity, wiping performance, water absorptivity, oilabsorptivity, moisture permeability, heat insulating properties,weatherability, high strength, high tear force, abrasion resistance,electrostatic controllability, drape, dye-affinity, safety and the like.In general, depending on the elongation properties of the firstprecursor web 20, the dimensions of apparatus 100 can be varied toproduce a web 1 having a wide range of dimensions associated with tufts6, including the height h (as shown in FIG. 3), and spacing (includingarea density of tufts 6). Additionally, the tufts may be easilypatterned into lines, filled forms, and selective regions of thelaminate web by having the desired pattern displayed in the teeth 110 onthe roll 104.

The laminate web 1 can comprise a lotion composition. A lotioncomposition on the body facing surface of an absorbent article has beenfound to be able to modulate skin properties and conditions for thewearer. The lotion composition can be a semisolid lotion that melts whenthe absorbent article is worn against a body. The lotion can be ahydrophobic semisolid lotion which can contribute to reducing rewet fromthe absorbent article to the wearer's body, thereby improving thewearing experience. The tufts 6 can be substantially free of lotion,thereby preserving the fluid acquisition properties of the tufts 6.Lotion composition can be applied to the laminate web 1 using a kissroll. Lotion composition can be applied to the caps 7. The lotioncomposition can comprise petrolatum. The lotion composition can includelotion compositions disclosed in U.S. Pat. No. 5,968,025; U.S. Pat. No.6,627,787; U.S. Pat. No. 6,498,284; U.S. Pat. No. 6,426,444; U.S. Pat.No. 6,586,652; U.S. Pat. No. 3,489,148; U.S. Pat. Nos. 6,503,526;6,287,581; U.S. Pat. No. 6,475,197; U.S. Pat. No. 6,506,394; U.S. Pat.No. 6,503,524; U.S. Pat. No. 6,626,961; U.S. Pat. No. 6,149,934; U.S.Pat. No. 6,515,029; U.S. Pat. No. 6,534,074; U.S. Pat. No. 6,149,932WO2000038747; or EP-A 927,050, or combinations thereof. The lotioncomposition can be applied such that more than about seventy fivepercent of said lotion composition by mass per square centimeter isapplied to said polymer film, That is, for a particular squarecentimeter of laminate comprising a lotion composition, more than aboutseventy five percent by mass is applied to the polymer film. The lotioncomposition can be applied such that more than about ninety percent ofsaid lotion composition by mass per square centimeter is applied to thepolymer film.

Web 1 may be used for a wide variety of applications, including variousfilter sheets such as air filter, bag filter, liquid filter, vacuumfilter, water drain filter, and bacterial shielding filter; sheets forvarious electric appliances such as capacitor separator paper, andfloppy disk packaging material; various industrial sheets such as tackyadhesive tape base cloth, oil absorbing material, and paper felt;various wiper sheets such as wipers for homes, services and medicaltreatment, printing roll wiper, wiper for cleaning copying machine, babywipers, and wiper for optical systems; various medicinal and sanitarysheets, such as surgical gown, gown, covering cloth, cap, mask, sheet,towel, gauze, base cloth for cataplasm, diaper, diaper liner, diapercover, feminine napkin covers, feminine napkin or diaper acquisitionlayer (underneath the cover layer), diaper core, tampon liners, tamponoverwraps, base cloth for adhesive plaster, wet towel, and tissue;various sheets for clothes, such as padding cloth, pad, jumper liner,and disposable underwear; various life material sheets such as basecloth for artificial leather and synthetic leather, table top, wallpaper, blind, wrapping, and packages for drying agents, shopping bag,suit cover, and pillow cover; various agricultural sheets, such asground covers and erosion control devices, cooling and sunlight-shielding cloth, lining curtain, sheet for overall covering,light-shielding sheet, wrapping materials of pesticides, underliningpaper of pots for seeding growth; various protection sheets such as fumeprevention mask and dust prevention mask, laboratory gown, and dustpreventive clothes; various sheets for civil engineering building, suchas house wrap, drain material, filtering medium, separation material,overlay, roofing, tuft and carpet base cloth, wall interior material,soundproof or vibration reducing sheet, and curing sheet; and variousautomobile interior sheets, such as floor mat and trunk mat, moldedceiling material, head rest, and lining cloth, in addition to aseparator sheet in alkaline batteries. Other uses include utilizing web1 as a wipe for personal cleansing or hygiene, such as for a baby wipe,facial cloth or wipe, or body cloth.

In one embodiment, web 1 or a composite comprising web 1 can be utilizedas a fecal material storage element. Web 1 can be utilized as asecondary topsheet or sublayer when it is disposed under an aperturedweb or film to accept and hold low viscosity feces or viscous bodilywaste away from a wearer's skin after defecation. Embodiments of thepresent invention having larger total three dimensional volume withinthe web or between the tufts 6 generally provide a greater capacity forstorage of low viscosity feces. Absorbent articles employing such fecalmaterial storage elements, or sublayers, are described in U.S. Pat. Nos.5,941,864; 5,957,906; 6,018,093; 6,010,491; 6,186,992; and 6,414,215,among others.

In one embodiment, web 1 comprises a nonwoven first precursor web 20comprising a spunbond nonwoven having a basis weight of about 80 gsm,and comprising polyethylene/polypropylene (sheath/core) bicomponentfibers having an average diameter of about 33 microns, and a secondprecursor web comprising a polyethylene film having a basis weight of 20gsm. In this embodiment, web 1 has about 24 tufts 6 per squarecentimeter, the tufts 6 having a plurality of looped, aligned fibers 8,each of which has an average fiber diameter of about 18 microns. A webof this type can be beneficially used as a topsheet for disposableabsorbent articles, as shown below with reference to FIG. 10. Forexample, such a web 1 is fluid impermeable except in the regions of thetufts 6 which can wick fluid from the first side 3 of web 1 to thesecond side 5.

FIG. 10 shows in partial cut away plan view a sanitary napkin having asone of its components a web 1 of the present invention. In general,sanitary napkin 200 comprises a backsheet 202, a topsheet 206 and anabsorbent core 204 disposed between the topsheet 206 and backsheet 202which can be joined about a the periphery 210. The topsheet 206 cancomprise web 1. The topsheet 206 can be in a facing relationship withthe absorbent core 204 and the first precursor web 20 from which thetufts 6 extend can be between the second precursor web 21 and theabsorbent core 204. Sanitary napkin 1 can have side extensions, commonlyreferred to as “wings” 208 designed to wrap the sides of the crotchregion of the panties of the user of sanitary napkin 1. Sanitarynapkins, including topsheets for use as the body facing surface thereof,are well known in the art and need no detailed description of variousalternative and optional designs. In addition to sanitary napkins, web 1can also be used in a diaper or adult incontinence product or otherdisposable hygiene products. However, it is noted that web 1 can be usedas, or as a component of, one or more of a backsheet, core material,topsheet, secondary topsheet, or wing material. Web 1 can also havemultiple layers and comprise a topsheet, secondary topsheet, core,backsheet, or any number of layers.

Web 1 might be especially useful as a topsheet 206 of sanitary napkin200. Web 1 might be beneficial as a topsheet 206 for sanitary napkinsdue to the combination of excellent fluid acquisition and distributionto the absorbent core 204, excellent prevention of rewet to thebody-facing surface of topsheet 206 when in use, and the ability of thecaps 7 to obscure fluid that is retained in the capillaries of tufts 6.Rewet can be a result of at least two causes: (1) squeezing out of theabsorbed fluid due to pressure on the sanitary napkin 200; and/or (2)wetness entrapped within or on the topsheet 206. In a desired topsheet206 both properties, fluid acquisition and fluid retention, aremaximized and rewet is minimized. Said differently, a desirable topsheetmight exhibit high rates of fluid acquisition, and low levels of rewet.

A topsheet 206 can be made by using a nonwoven first precursor web 20and a fluid impermeable polyethylene film second precursor web 21. Thebasis weights of the component webs can be varied, however, in generaldue to cost and benefit considerations a total basis weight of betweenabout 20 gsm and 80 gsm is desirable for web 1. When made as afilm/nonwoven laminate, web 1 can combine the softness and fluidcapillarity of fiber tufts and the rewet prevention of a fluidimpermeable polymer film. When a sanitary napkin is used having atopsheet 206 comprising web 1 with first side 3 being the body-facingside, and the second side 5 being in fluid communication with anunderlying absorbent core, fluid can be acquired by tufts 6 on firstside 3 of web 1 and wicked through second precursor web 21 to secondside 5 of web 1 which can then be desorbed to the absorbent core 204.Because tufts 6 are discrete and spaced apart, and are separated by afluid impermeable second precursor web 21, rewet can be minimized.Alternatively, web 1 could be used with first side 3 being the fluidcommunication side and second side 5 being the body-facing side. Thisenables the discontinuities 16 to potentially allow fluid to betransported into or through the tufts 6.

FIG. 11 shows in partial cut away perspective view a catamenial tampon300 having as one of its components a web 1 of the present invention. Ingeneral, tampon 300 comprises a compressed absorbent core 302 and afluid permeable cover wrap 304 that covers absorbent core 302. Coverwrap 304 may extend beyond one end of absorbent core 302 to form a skirtportion 306. A removal means, such as string 308 can be provided tofacilitate removal of the tampon after use. Tampons, including coverwraps for use as the body contacting surface thereof, are well known inthe art and need no detailed description of various alternative andoptional designs. However, it is noted that web 1 can be used as, or asa component of, one or more of a cover wrap, absorbent core material, orremoval means material.

FIG. 12 is a top view scanning electron micrograph (SEM) of a laminateweb as disclosed herein. As shown in FIG. 12, a cap 7 covers the distalportion 31 of at least part of a particular tuft 6. In FIG. 12, the capintegrally extends from at least two extension locations 54 on oppositesides of the tuft 6. The extension locations 54 are separated by thefirst opening 51 and the second opening 52. When viewed from above, thecap 7 covering the distal portion 31 of a particular tuft can helpobscure from view fluid, such as menses, held within the capillaries ofthe fibers 8 forming tuft 6. Also shown in FIG. 12 is microtexture inthe polymer web, the microtexture being microapertures 72.

FIG. 13 is a profile view SEM of a laminate web as disclosed herein. Asshown in FIG. 13, cap base 71 proximal the first side 3 of laminate web1 is narrower than a portion of the cap 7 away from the cap base 71. Thecap 7 in FIG. 13 is generally omega (Ω) shaped.

FIG. 14 is an elevated profile view SEM of a laminate web as disclosedherein. As shown in FIG. 14, the cap 7 can have more than two openingssuch that the cap extends from the first precursor web 21 (polymer film)at more than two discrete locations.

A laminate web 1 that could be used as a topsheet 206 or cover wrap 304can be fabricated using the apparatus disclosed herein. A suitablematerial for first precursor web 20 can be a BBA Bico, 28 gsm, GCAS95001796, 50/50 PE/PP, philic nonwoven, available from BBA Nonwovens. Asuitable material for the second precursor web 21 could be TredegarX-33350 (philic) which is a 100 mesh precursor web, obtainable fromTredegar Corp. Two sets of process parameters listed in Table 1 could beemployed to form the laminate web disclosed herein. The teeth 110 couldhave a uniform circumferential length dimension TL of 0.120 inchesspaced from one another circumferentially by a distance TD of 0.060 in.,a pitch P of 0.060 in., a depth of engagement E of 0.114 in., a toothheight TL of 0.185 in, a radius of curvature at the tips of teeth 110and grooves 108 of 0.005 in, and the radius of curvature in the valleysbetween teeth 110 and grooves 108 of 0.015 in. The temperature of thenonwoven in could be about 25° C. The temperature of the polymer film incould be higher than 25° C. Having the temperature of the polymer filmabove 25° C., for instance about 50° C., may provide for formation ofcaps 7. In general, it is thought that modulus of the materialsprocessed, temperature, microtexture of the polymer film, and the webtensions on the upstream side and downstream side of the apparatus mightbe factors that affect the resulting structure of the laminate.

TABLE 1 Elastic Relaxed Speed Tension Modulus (N/m) Width (mm) (m/min)Strain (N) Process 1 Nonwoven In 4043 165 367.0 1.021 13.98 Polymer Film1478 176 367.0 1.021 1.42 In Laminate Out 176 364.3 1.014 9.93 Process 2Nonwoven In 1896 165 367.0 1.029 9.16 Polymer Film 1478 176 367.0 1.0211.42 In Laminate Out 176 364.3 1.02 7.71

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1.-6. (canceled)
 7. The laminate web according to claim 21, wherein saidpolymer film has a polymer film thickness and said cap has a capthickness, wherein said cap thickness of a portion of said cap is lessthan said polymer film thickness.
 8. The laminate web according to claim21, wherein said polymer film is a microtextured polymer film comprisingmicrofeatures, wherein a plurality of said microfeatures are betweensaid tufts, wherein said microfeatures are microapertures ormicrobubbles.
 9. The laminate web according to claim 21, wherein saidlaminate web comprises a lotion composition, wherein more than aboutseventy five percent of said lotion composition by mass per centimetersquared is applied to said polymer film.
 10. The laminate web accordingto claim 21, wherein said fibrous web is relatively hydrophilic ascompared to said polymer film.
 11. The laminate web according to claim21, wherein said cap is tunnel shaped. 12-20. (canceled)
 21. A laminateweb comprising a fibrous web in facing relationship with a polymer film,said laminate web comprising a first side comprising: (a) a plurality ofpolymer film ruptures each of which accepting a tuft of fibers extendingtherethrough, said tuft of fibers comprising fibers integral with andextending from said fibrous web, wherein each of said tufts of fiberscomprises a tuft distal portion; (b) at least one film extension sectionadjacent each of said plurality of polymer film ruptures that coverssaid tuft distal portion to define a capped tuft comprising a cap havinga cap length and a cap width; and (c) an opening positioned along saidcap length of at least some of said capped tufts, so as to expose fibersfrom the underlying tuft of fibers.
 22. A laminate web comprising afibrous web in facing relationship with a polymer film, said laminateweb comprising a first side comprising: (a) a plurality of polymer filmruptures each of which accepting a tuft of fibers extendingtherethrough, said tuft of fibers comprising fibers integral with andextending from said fibrous web, wherein each of said tufts of fiberscomprises a tuft distal portion; (b) at least one film extension sectionadjacent each of said plurality of polymer film ruptures that coverssaid tuft distal portion to define a capped tuft comprising a cap havinga cap length and a cap width; and (c) wherein at least some of saidcapped tufts comprise, along said cap length, exposed fibers from theunderlying tuft of fibers.
 23. A laminate web comprising a fibrous webin facing relationship with a polymer film, said laminate web comprisinga first side comprising: (a) a plurality of polymer film ruptures eachof which accepting a tuft of fibers extending therethrough, wherein eachof said plurality of polymer film ruptures comprises opposing first andsecond edges, and wherein said tuft of fibers comprises fibers integralwith and extending from said fibrous web to define a tuft distalportion; (b) a first film extension adjacent said first edge; (c) asecond film extension adjacent said second edge; (d) a third filmextension adjacent said second edge and spaced apart from said secondfilm extension; and (e) a cap covering said tuft distal portion, saidcap comprising a portion of at least one of said first film extension,said second film extension, and said third film extension.
 24. Alaminate web comprising a fibrous web in facing relationship with apolymer film, said laminate web comprising a first side comprising: (a)a plurality of polymer film ruptures each of which accepting a tuft offibers extending therethrough, said tuft of fibers comprising fibersintegral with and extending from said fibrous web, wherein each saidtufts of fibers comprises a tuft distal portion; (b) at least one filmextension section adjacent each of said plurality of polymer filmruptures that covers said tuft distal portion to define a capped tuftcomprising a cap having a cap length; and (c) wherein at least some ofsaid capped tufts comprise first and second openings situated at eitherend of said cap length, and a third opening, each of said first, second,and third openings exposing fibers from the underlying tuft of fibers.25. An absorbent article comprising: (a) an absorbent core; and (b) alaminate web according to claim 22, wherein said fibrous web facestowards said absorbent core and said polymer film faces away from saidabsorbent core.